Systems and methods for controlling phasing of advancing substrates in absorbent article converting lines

ABSTRACT

The present disclosure relates to systems and processes for controlling the relative positions or phasing of advancing substrates and/or components in absorbent article converting lines. The systems and methods may utilize feedback from technologies, such as vision systems, sensors, remote input and output stations, and controllers with synchronized embedded clocks to accurately correlate component placement detections and placement control on an absorbent article converting process. The systems and methods may accurately apply the use of precision clock synchronization for both instrumentation and control system devices on a non-deterministic communications network. In turn, the clock synchronized control and instrumentation network may be used to control the substrate position. As such, the controller may be programmed to the relative positions of substrates and components along the converting line without having to account for undeterminable delays.

FIELD OF THE INVENTION

The present disclosure relates to systems and methods for manufacturingdisposable absorbent articles, and more particularly, systems andmethods for controlling the phasing of advancing components andsubstrates in absorbent article converting lines.

BACKGROUND OF THE INVENTION

Along an assembly line, diapers and various types of other absorbentarticles may be assembled by adding components to and otherwisemodifying an advancing, continuous web of material. For example, in someprocesses, advancing webs of material are combined with other advancingwebs of material. In other examples, individual components created fromadvancing webs of material are combined with advancing webs of material,which in turn, are then combined with other advancing webs of material.Once the desired component parts are assembled, the advancing web(s) andcomponent parts are subjected to a final knife cut to separate theweb(s) into discrete diapers or other absorbent articles. The discretediapers or absorbent articles may also then be folded and packaged.

In some manufacturing operations, a continuous base web of material isadvanced in a machine direction along a converting line. Discretecomponents and continuous webs are combined with the base web ofmaterial to form a continuous length of absorbent articles. In someinstances, discrete components are supplied at a relatively consistentseparation distance or pitch before being combined with the base web. Assuch, it may be necessary to accurately control the position at whichthe discrete components are supplied to help ensure that the componentsare applied at desired locations on the base web. As such, some controlsystems may utilize sensors to monitor positions of the components onthe base web to determine if the components are properly positioned withrespect to the base web. As the base web advances, the components passby a sensor that detects the presence the components. The sensorprovides a feedback signal that corresponds to when a component isdetected. A controller receives the feedback signal from the sensor andcompares the feedback signal with a setpoint. Based on the comparison,the controller may alter the positions at which the components are addedto the base web by temporarily changing the speed at which thecomponents are supplied or by commanding a position move offset.

At relatively low web speeds, the control system may have adequate timeto accurately monitor and change the component positions relative to thebase web in response to feedback signals from the sensor. However, atrelatively high base web speeds, time delays within the control systemmay result in unstable and/or inaccurate control of component placement.In turn, unstable and/or inaccurate base position control may result indamaged and/or defective absorbent articles. There may be varioussources of time delays within the control system, such as time delaysassociated with the sensor and/or control loops. Some systems mayattempt to compensate for the time delays by requiring the convertingline to operate at relatively low base web speeds, which results inrelatively lower production rates. Other systems may attempt tocompensate for the time delays by utilizing high speed sensors, whichmay add to the complexity and cost of the manufacturing operation.

SUMMARY OF THE INVENTION

The present disclosure relates to systems and processes for controllingthe relative positions or phasing of advancing substrates and/orcomponents in absorbent article converting lines. The systems andmethods may utilize feedback from technologies, such as vision systems,sensors, remote input and output stations, and controllers withsynchronized embedded clocks to accurately correlate component placementdetections and placement control on an absorbent article convertingprocess. The systems and methods may accurately apply the use ofprecision clock synchronization for both instrumentation and controlsystem devices on a non-deterministic communications network. In turn,the clock synchronized control and instrumentation network may be usedto control the substrate position. As such, the controller may beprogrammed to the relative positions of substrates and components alongthe converting line without having to account for undeterminable delays.

In one form, a method for phasing absorbent products from a webconverting manufacturing process includes the steps of: providing acommunication network; connecting a sensor with the communicationnetwork, the sensor including a sensor clock; connecting a controllerwith the communication network, the controller including a controllerclock; synchronizing the sensor clock with the controller clock suchthat the reported time of the controller clock and the sensor clock arecorrelated; advancing a substrate in a machine direction through aconverting process at a first speed; virtually segmenting the substrateinto a plurality of virtual products along the machine direction;virtually dividing the virtual products into a plurality of virtualsegments along the machine direction; advancing a series of componentparts in the machine direction at a second speed, the component partsspaced from each other at a relatively constant distance; sequentiallyadding component parts to the substrate; inspecting the substrate andcomponent parts with the sensor; communicating inspection parametersfrom the sensor to the communication network; assigning a timestamp toeach inspection parameter, each timestamp based on the sensor clock;receiving the inspection parameters and corresponding timestamps fromthe communication network into the controller; correlating eachinspection parameter with one virtual segment based on the timestamp ofthe inspection parameter; identifying component positions in virtualsegments based on the inspection parameters; adjusting the placement ofthe component parts on the virtual products; cutting the substrate withcomponent parts added thereto into discrete absorbent articles; andpackaging the discrete absorbent articles.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of an absorbent article convertingline and reject system.

FIG. 2 is a top view of an advancing substrate showing virtual productsand virtual segments.

FIG. 3A is a schematic side view of a converting line, substrate, andcomponents.

FIG. 3B is a top view of the substrates and components that correspondswith FIG. 3A.

FIG. 4A is a schematic side view of a converting line, substrate, andcomponents.

FIG. 4B is a top view of the substrates and components that correspondswith FIG. 4A.

FIG. 5A is a schematic side view of a converting line, substrate, andcomponents.

FIG. 5B is a top view of the substrates and components that correspondswith FIG. 5A.

FIG. 6A is a schematic side view of a converting line, substrate, andcomponents.

FIG. 6B is a top view of the substrates and components that correspondswith FIG. 6A.

FIG. 7 is a top plan view of a disposable absorbent article that mayinclude one or more substrates and/or components monitored andconstructed in accordance with the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. “Diaper” isused herein to refer to an absorbent article generally worn by infantsand incontinent persons about the lower torso. The term “disposable” isused herein to describe absorbent articles which generally are notintended to be laundered or otherwise restored or reused as an absorbentarticle (e.g., they are intended to be discarded after a single use andmay also be configured to be recycled, composted or otherwise disposedof in an environmentally compatible manner).

The term “disposed” is used herein to mean that an element(s) is formed(joined and positioned) in a particular place or position as amacro-unitary structure with other elements or as a separate elementjoined to another element.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a layer or layers or fibrousmaterials, films and foils such as plastic films or metallic foils thatmay be used alone or laminated to one or more web, layer, film and/orfoil. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, and the like.Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. The term “cross direction”(CD) is used herein to refer to a direction that is generallyperpendicular to the machine direction.

The present disclosure relates to systems and processes for controllingthe relative positions or phasing of advancing substrates and/orcomponents in absorbent article converting lines. In particular, thesystems and methods herein focus on creating a more accurate controlsystem with improved set-up, position detection, tracking, andvalidation algorithms. For example, the systems and methods may utilizefeedback from technologies, such as vision systems, sensors, remoteinput and output stations, and controllers with synchronized embeddedclocks to accurately correlate component placement detections andplacement control on an absorbent article converting process. As such,the systems and methods may accurately apply the use of precision clocksynchronization for both instrumentation and control system devices on anon-deterministic communications network, such as for example, anEthernetIP network. In turn, the clock synchronized control andinstrumentation network may be used to control the substrate position.As such, the controller may be programmed to the relative positions ofsubstrates and components along the converting line without having toaccount for undeterminable delays. In addition, the controller may beprogrammed to virtually divide the substrate along the machine directionMD into virtual segments based on the position of the substrate andanticipated clock inaccuracies.

Although the present disclosure is provided in the context ofmanufacturing absorbent articles, and diapers in particular, it is to beappreciated that the systems and methods disclosed herein may be appliedto the manufacture of various types of articles and products involvingthe monitoring of various different types of substrates and/orcomponents. Examples of other products include absorbent articles forinanimate surfaces such as consumer products whose primary function isto absorb and retain soils and wastes that may be solid or liquid andwhich are removed from inanimate surfaces such as floors, objects,furniture and the like. Non-limiting examples of absorbent articles forinanimate surfaces include dusting sheets such as the SWIFFER cleaningsheets, pre-moistened wipes or pads such as the SWIFFER WETpre-moistened cloths, paper towels such as the BOUNTY paper towels,dryer sheets such as the BOUNCE dryer sheets and dry-cleaning clothessuch as the DRYEL cleaning clothes all sold by The Procter & GambleCompany. Additional examples of products include absorbent articles foranimate surfaces whose primary function is to absorb and contain bodyexudates and, more specifically, devices which are placed against or inproximity to the body of the user to absorb and contain the variousexudates discharged from the body. Non-limiting examples of incontinentabsorbent articles include diapers such as PAMPERS diapers, training andpull-on pants such as PAMPERS FEEL 'N LEARN and EASY UPS, adultincontinence briefs and undergarments such as ATTENDS adult incontinencegarments, feminine hygiene garments such as panty liners, absorbentinserts, and the like such as ALWAYS and TAMPAX, toilet paper such asCHARMIN toilet paper, tissue paper such as PUFFS tissue paper, facialwipes or clothes such as OLAY DAILY FACIAL wipes or clothes, toilettraining wipes such as KANDOO pre-moistened wipes, all sold by TheProcter & Gamble Company. Still other examples of products includepackaging components and substrates and/or containers for laundrydetergent and coffee, which may be produced in pellets or pouches andmay be manufactured in a converting or web process or even discreetproducts produced at high speed such as high-speed bottling lines orcosmetics. Still other examples of products include a web substratecontaining labels to be placed on bottles and/or containers for laundrydetergent (such as Tide, Gain, etc.), fabric enhancers (such asFebreeze, Downy, etc.), hair and beauty care products (such as Head &Shoulders, Old Spice deodorant/antiperspirant, Herbal Essence, Pantene,etc.), and cleaning products (such as Mr. Clean, Cascade, Dawn, Ivory,etc.). Further, it is to be appreciated that although the presentdisclosure often refers to monitoring or viewing substrates and/or webs,it is to be appreciated that the control systems discussed herein can beused to monitor and/or view combinations of webs and individualcomponents as well as parts added as a continuous web of material andparts added as a discontinuous web of material.

FIG. 1 shows a schematic representation of an absorbent articleconverting process including a converting line or machine 100 configuredto manufacture diapers. It is to be appreciated that the systems andmethods disclosed herein are applicable to work with various types ofconverting processes and/or machines. As shown in FIG. 1, the convertingline 100 may include one or more motors 102 that drive transportsystems, such as a nip roll 104, to move diaper substrates and componentmaterials through the manufacturing process. For example, FIG. 1 showsfor example, a base substrate 106 and two auxiliary substrates and/orcomponents 108 of material used to construct portions of the diapers.The substrates may be provided as rolls and fed into the converting line100. It is to be appreciated that material of the auxiliary substratesmay be supplied in various ways. For example, FIG. 1 shows a firstauxiliary substrate 110 in the form of a continuous substrate 112, and asecond auxiliary substrate 114 in the form of individual components 116.It is to be appreciated that the auxiliary substrates 110 may betransferred to the base substrate 106 through various types of transfermechanisms. For example, the individual components 116 are shown asbeing transferred to the base substrate via a transfer mechanism 118 inthe form of a servo patch placer mechanism 120, such as disclosed inU.S. Pat. Nos. 6,450,321; 6,705,453; 6,811,019; and 6,814,217. It isalso to be appreciated that the various substrates can be used toconstruct various components of the absorbent articles, such asbacksheets, topsheets, absorbent cores, front and/or back ears, fastenercomponents, and various types of elastic webs and components such as legelastics, barrier leg cuff elastics, and waist elastics. Exemplarydescriptions of absorbent article components are provided below withreference to FIG. 7. Referring back to FIG. 1, as the base substrate 106advances through the converting line 100, the base substrate 106 iscombined with the auxiliary substrates 108 and/or discrete components116 to create a continuous length of absorbent articles 122. At adownstream portion of the converting process 100, the continuous lengthof absorbent articles 122 is subjected to a final knife 124 and cut tocreate separate and discrete absorbent articles 126 in the form ofdiapers 128. As discussed in more detail below, a phasing control systemmay be used to ensure that substrates and/or components are applied tothe base substrate in desired locations.

As shown in FIG. 1, defective articles 130 may be subject to a rejectionsystem 132 and removed from the process. For example, FIG. 1 showsdefective diapers 130 being channeled to a reject bin 136. Diapers 134that are not deemed to be defective may be subject to further processingsteps, such as folding and packaging. For example, FIG. 1 showsnon-defective diapers advancing from the final knife to a foldingmechanism 138. In some embodiments, a pneumatic system may be used toremove defective absorbent articles from the assembly line. Moreparticularly, after application of the final knife and before beingfolded by a folding mechanism, defective articles are removed from theassembly line by a blast of compressed air discharged from the pneumaticsystem. In other embodiments, defective articles may be allowed toadvance from the final knife, partially through a folding mechanism, andinto a reject bin. Such a system, described for example in U.S. PatentPublication No. US20080223537A1, may stop or slow the motion of tuckerblades on the folding mechanism such that a rejected article will passthrough a portion of the folding mechanism without being folded and fallinto a reject bin. After the defective articles have passed through thefolding mechanism, motion of the tucker blades is resumed, allowing thetucker blades to engage non-defective articles and causing thenon-defective articles to be folded and channeled toward a packagingprocess downstream of the folding mechanism.

As shown in FIG. 1 and as described in more detail below, varioussensors 140 and other devices may be arranged adjacent the convertingline 100 may communicate with a controller 142. Based on suchcommunications, the controller 142 may monitor and affect variousoperations on the converting line 100. As discussed in more detailbelow, the controller 142 may send speed change or position move offsetcommands 1002 to the transfer mechanism 118 based on communications withthe sensors 140. In the systems and methods described herein, thecontroller includes a computer system. The computer system may, forexample, include one or more types of industrial programmable logiccontroller (PLC) and/or personal computer (PC) running software andadapted to communicate on an EthernetIP network. Some embodiments mayutilize industrial programmable controllers such as the Siemens S7series, Rockwell ControlLogix, SLC or PLC 5 series or Mitsubishi Qseries. The aforementioned embodiments may use a personal computer orserver running a control algorithm such as Rockwell SoftLogix orNational Instruments Labview or may be any other device capable ofreceiving inputs from sensors, performing calculations based on thoseinputs and generating control actions through servomotor controls,electrical actuators or electro-pneumatic, electrohydraulic or otheractuators.

As the substrates and components travel in the machine direction MDthrough the converting line, the controller tracks the advancement ofthe substrates and components. In some embodiments such as shown in FIG.1, the controller 142 may track the advancement with counts generated bya machine axis 144 that correspond with machine direction positions onsubstrates and components while advancing though the converting line100. In some configurations, the machine axis 144 may be configured asan actual motor 146 that provides count signals to the controller 142.The controller may utilize rotational speed, time, and/or count datafrom the machine axis 144 that correspond with the machine directionspeed and travel of the substrates and components through the convertingline.

It is to be appreciated that instead of or in addition to utilizingfeedback from a physical machine axis as discussed above, the rotationalmotion of the machine axis 144 may be simulated by software in thecontroller. For example, in FIG. 1, the controller 142 can utilizecounts generated by a virtual machine axis 148 in the controllersoftware. More particularly, the virtual machine axis 148 may beprogrammed to imitate a motor that generates counts as the motorrotates. As such, it is to be appreciated that the machine axis referredto herein may be either a virtual axis existing in software or aphysical axis corresponding with the rotational motion of a motor orother equipment.

As discussed above, the machine axis may 144 be configured to correlatethe linear motion of the substrates and components in the machinedirection MD through the converting line 100 with counts correspondingwith rotation of the machine axis 144. In some embodiments, one completerotation of the machine axis 144 and associated count data correspondwith one pitch length of an absorbent article 126. In some embodiments,the pitch lengths of the absorbent articles are the machine directionlongitudinal lengths of the individual absorbent articles beingproduced. FIG. 7 shows an example of a longitudinal pitch length PL of adiaper. As such, the controller 142 may use counts generated from themachine axis 144 to virtually divide the substrates and components intovirtual products 150. As shown in FIG. 2, the virtual products 150 mayhave machine direction lengths 151 that correspond with the pitchlengths of products being produced. For example, FIG. 2 shows a top sideview of the base substrate 106 divided into virtual products 150 alongthe machine direction MD by the controller 142. Count signalscorresponding with rotation of the machine axis that correspond withless than a complete rotation can also be used by the controller divideeach virtual product 150 into virtual segments 152, such as shown inFIG. 2. As discussed in more detail below, the substrate speed andestimated clock inaccuracies can be used to determine the length of theeach virtual segment in the machine direction MD, and in turn, thenumber of virtual segments in each virtual product. For example, FIG. 2shows one virtual product 150 divided into twenty virtual segments 152.As discussed in more detail below, the controller 142 can also utilizesignals from the inspection sensor 140 that correspond with thepositions of components in virtual products and segments and makeadjustments to the placement of components within the virtual products.

As previously mentioned, the systems and methods herein can utilizevarious types of sensors to monitor the substrates and componentstraveling through the converting line. As shown in FIG. 1, various typesof inspection sensors 140 may be used to perform various functions. Forexample, inspection sensors 140 may be used to detect registrationfeatures, the relative placement of substrates and/or components, andvarious types of defects. As discussed in more detail below, based onthe detections of the inspection sensors 140, feedback signals from theinspection sensors in the form of inspection parameters 1000 arecommunicated to the controller 142. For example, as shown and discussedin more detail below with reference to FIGS. 3A-6B, a sensor 140 can beconfigured to detect a relative position 164 of a component 158 on asubstrate 106 and communicate an inspection parameter 1000 correspondingwith the relative position 164 to the controller 142. It is also to beappreciated that various types of controllers and inspection sensors canbe configured in various ways to provide various types of data andperform various functions, for example, such as disclosed in U.S. Pat.Nos. 5,286,543; 5,359,525; 6,801,828; 6,820,022; and 7,123,981 andEuropean Patent No. EP 1528907B1.

It is to be appreciated that various different types of inspectionsensors 140 may be used to detect the relative positions 164 and monitorthe substrates and components while advancing through the convertingline 100. For example, inspection sensors 140 may be configured asphoto-optic sensors that receive either reflected or transmitted lightand serve to determine the presence or absence of a specific material;metal-proximity sensors that use electromagnetic to determine thepresence or absence of a ferromagnetic material; capacitive or otherproximity sensors using any of a number of varied technologies todetermine the presence or absence materials. Inspection sensors 140 mayalso be configured as vision systems and other sub-processing devices toperform detection and, in some cases, logic to more accurately determinethe status of an inspected product. Particular examples of inspectionsensors 140 may include simple vision based sensors such as CognexChecker series, integrated smart camera systems such as Cognex Insight,DVT Legend or Keyence smart cameras, component vision systems such asNational Instruments CVS vision systems or PC based vision system suchas Cognex VisionPro or any other vision system software which can run ona PC platform.

It should also be appreciated that inspection parameters 1000corresponding with the detection of component positions 164 may beprovided from inspection sensors 140 in various forms. In oneembodiment, inspection parameters 1000 may be in the form “results,”such as for example, provided from a sensor state change resulting in abinary input corresponding with the detected presence or absence of acomponent 158. In some embodiments, inspection parameters 1000 may beprovided in the form of measurements and/or numerical indications ofdetected positions of components relative to components and/orsubstrates; and/or numerical indications of the positions of componentsand/or substrates relative to other physical or virtual references. Inother embodiments, inspection parameters 1000 may be in the form ofimages transferred via a standard protocol such as ftp (File TransferProtocol), DDE (Dynamic Data Exchange), or OPC (Object Linking andEmbedding for Process Control). Thus, it is to be appreciated thatvarious types of component features 162 can be used to indicate therelative positions 164 with the systems and methods herein. Suchcomponent features 162 may include any signaling mechanism that isrecognizable by a machine. For example, the component features 162 mayinclude an edge or physical discontinuity such as notch, a protrusion, adepression, or a hole formed in a substrate and/or components. In someconfigurations, the component features 162 may include a region ofmagnetic discontinuity, electrical discontinuity, electromagneticdiscontinuity, and/or any combination thereof. Some component features162 may provide an optical marker that operates on the basis ofproviding detectable changes in intensities of visible and/ornon-visible wavelengths of light. Various examples of registrationfeatures are provided in U.S. Pat. Nos. 5,286,543; 6,444,064; and6,955,733. Component features 162 may be configured to operativelyindicate the boundaries between individual components 158. In someconfigurations, the components 158 are regularly spaced at substantiallyequal intervals, component pitch 166, along machine direction of asubstrate. As shown in FIGS. 3A-6B, components 158 in the form of diaperears are positioned adjacent lateral side edges of the first substrate106.

As shown in FIG. 1, the inspection sensors 140 are connected with thecontroller 142 through a communication network 154, which allows theinspection sensors 140 to communicate inspection parameters 1000 to thecontroller 142. As discussed in more detail below, devices thatcommunicate on the network each include precision clocks that aresynchronized to a master clock within some specified accuracy. As shownin FIG. 1, the inspection sensors 140 and the controller 142 may beconnected directly with the communication network 154. As such, eachsensor or other field device connected directly with the communicationnetwork 154 may include a clock. Inspection sensors 140 that include aclock and that may be connected directly with the communication network154 may include, for example, vision systems such as NationalInstruments PXI or any PC-based vision system such as Cognex VisionPro.Such sensors may also include other controllers that may be configuredas peers to the controller or may be configured as subordinate to thecontroller.

In some embodiments, the inspection sensors 140 may be indirectlyconnected with the communication network 154. For example, theinspections sensors 140 may be connected with the communication network154 through a remote input and output (I/O) station 156. When utilizingremote I/O stations 156, the inspection sensors 140 may be hardwired tothe remote I/O stations, and in turn, the remote I/O stations 156 areconnected with the communication network 154. As such, the each remoteI/O station 156 may include a precision clock. Example remote I/Ostations 156 or other IEEE-1588 based instruments that can be utilizedwith systems and methods herein include, for example a NationalInstruments PCI-1588 Interface (IEEE 1588 Precision Time ProtocolSynchronization Interface) that synchronizes PXI systems, I/O modulesand instrumentation over Ethernet/IP or a Beckhoff Automation EtherCatand XFC technology (eXtreme Fast Control Technology).

As previously mentioned, each device, such as the inspection sensors140, remote I/O stations 156, and the controller 142, connected with thecommunication network 154 includes a clock, and each clock issynchronized to a master clock. In one configuration, the controllerincludes the master clock, referred to herein as a controller masterclock, and all other clocks of devices connected with the communicationnetwork are referenced to the controller master clock. In such aconfiguration, the remote I/O stations and inspection sensors eachinclude a clock, referred to herein as a sensor clock, which issynchronized to the controller master clock. Inspection parametersprovided by the inspection sensors and communicated to the communicationnetwork are time-stamped with the time from the clocks on thecorresponding sensors and remote I/O stations. In turn, the inspectionparameters and corresponding timestamp data is sent to the controllerover the communication network 154. Thus, the controller 142 can beprogrammed to evaluate the inspection parameter 1000 based on the actualtime the inspection parameter was provided by the inspection sensor 140.Therefore, ambiguity as to when detections were actually made by aninspection sensor 140 is relatively small.

As previously mentioned, all clocks that are used to determine andreport timestamps may be synchronized together. Clock synchronizationallows the reported time from one device on the communication network154 to be utilized by another device on the communication network. Whenthe clocks are synchronized, ambiguity as to when an inspectionparameter 1000 was actually provided by the inspection sensor 140 isaffected only by the accuracy of the clocks with respect to each other.The clocks of the devices on the communication network may besynchronized in various ways depending on the type of communicationnetwork used.

In one embodiment, the communication network 154 is configured as anon-deterministic communication network, such as for example, Ethernetor Ethernet IP (industrial protocol) communication network. When usingan Ethernet IP communication network, the clocks of each device may besynchronized using the IEEE1588 precision time protocol, described inIEEE1588 Standard, “Precision Clock Synchronization Protocol forNetworked Measurement and Control Systems” and also described inRockwell Automation publication number 1756-WPO05A-EN-E, publishedJanuary 2009, and entitled “An Application of IEEE 1588 to IndustrialAutomation.” As mentioned above, timestamps associated with inspectionparameters from any inspection sensor may be referenced to the masterclock, which allows the relative time as to when the inspectionparameters were provided to be accurately calculated. In oneconfiguration, the controller includes the master clock, the controllermaster clock, and all other clocks of devices connected with thecommunication network, the sensor clocks, are referenced to thecontroller master clock. As a result, the time as to when an inspectionparameter was provided from an inspection sensor can be can be reportedto the controller within the accuracy of an IEEE1588 compliant clock. Insome embodiments, reported timestamps may be accurate to within 0.1milliseconds of the controller master clock. In another configuration,another device, such as an Ethernet switch or router is the local masterclock. In this case, both the controller clock and the sensor clockfollow the local master clock. The identity of the local master isunimportant since all clocks in the system are synchronized to the localmaster within the IEEE1588 PTP standard.

With reference to the above description and figures, the methods andsystems herein utilize a controller 142 and one or more inspectionsensors 140 connected with a communication network 154. Each sensor 140,and remote I/O device 156, if used, have clocks that are synchronizedwith the master controller clock in the controller. The controller 142tracks the movement of the substrates and components traveling in themachine direction of the converting line 100. More particularly,controller 142 utilizes feedback from the machine axis 144 to virtuallydivide the substrates and components into virtual products 150 along themachine direction, track the movement of virtual products 150 in themachine direction, and correlate the virtual products 150 to actualindividual products 126 produced after the final knife 124 cut. Inaddition, the controller 142 utilizes feedback from the machine axis 144to virtually divide the virtual products 150 into virtual segments 152along the machine direction. The inspection sensors 140 provideinspection parameters 1000 to the controller 142 via the communicationnetwork 154. As discussed above, the inspection parameters 1000 can beconfigured to indicate the positions of components and/or substraterelative to other components and/or substrates. The sensors 140 provideinspection parameters 1000 to the communication network along withassociated timestamp from the sensor clocks. The controller receives theinspection parameters 1000 and associated timestamps from thecommunication network 154 and correlates the inspection parameters withthe corresponding virtual products 150 and/or virtual segment 152 movingalong the converting line 100. As discussed in more detail in theexample below, if the controller determines that components 158 arebeing applied to a substrate in the incorrect positions on a virtualproduct 150, the controller will send a temporary speed change orposition move offset command 1002 to the transfer mechanism 118.

To provide additional context to the above discussion, the followingprovides a specific description of one example implementation of thesystems and processes herein. FIGS. 3A-6B show an example of anabsorbent article converting line 100 as substrates and componentstravel along the machine direction MD to a final knife cut 124 and afolding and/or packing system 138. In particular, FIGS. 3A, 4A, 5A, and6A show schematic side views of the converting line 100, substrate 106,108 and components 116, and FIGS. 3B, 4B, 5B, and 6B show top views ofthe substrates 106 and registration features 153 that correspond withFIGS. 3A, 4A, 5A, and 6A, respectively. For the purposes of thediscussion relating to FIGS. 3A-6B, the converting line 100 is describedin the context of a diaper converting line. In particular, a basesubstrate 106 is shown to enter and advance in the machine direction MDthrough the converting line 100. Material from an auxiliary substrate108 is cut into individual components 116, transferred and bonded to thebase substrate 106 to form features 158 on the base substrate 106, suchas for example, front ears on a diaper. FIGS. 3A, 4A, 5A, and 6A alsoshow an inspection sensor 140, controller 142, machine axis 144, padreject system 132, and folding system 138 associated with the convertingline 100. In accordance with the above description, the machine axis 144is shown schematically in the form of a virtual axis 148 that providesbase web position and speed signals to the controller 142. In turn, thecontroller 142 divides the base web into virtual products 150 along themachine direction MD. For the purposes of the present description, FIGS.3A-6B show only three virtual products 150. Also in accordance with theabove discussion, the inspection sensor 140 is connected with a remoteI/O station 156. In turn, the remote I/O station 156 and controller 142are connected with a communication network 154, in the form of anEthernet IP network. It is to be appreciated that the more thaninspection sensor 140 may be used and that some or all inspectionsensors may be connected directly with the communication network 154without using a remove I/O station. The remote I/O station includes aclock 1006, referred to herein as a sensor clock 1008 providing a time,Ts, and the controller includes a clock 1006, referred to herein as themaster control clock 1010 providing a time, Tc. The sensor clock 1008 issynchronized with the master control clock 1010, such that Ts is set toequal Tc.

As shown in FIGS. 3A-6B, the lengths 151 of the virtual products 150 inthe machine direction correspond with the pitch lengths PL of productsbeing produced. The lengths 151 of the virtual products are defined bythe distances between a virtual leading edge 168 and a virtual trailingedge 170 on each virtual product. In particular, the lengths of virtualproducts 150 a, 150 b, 150 c are defined by the distances betweenvirtual leading edges 168 a, 168 b, 168 c and virtual trailing edges 170a, 170 b, 170 c, respectively. For the purposes of discussion, it isassumed that virtual product pitch length is 600 mm and the base webtravels in the machine direction at a speed of 300 meters per minute, or500 products per minute. In the present example, it is assumed that thevirtual machine axis 148 is configured to generate counts simulating onecomplete one rotation that corresponds with a one pitch lengthadvancement of the base substrate 106 in the machine direction. As such,one complete rotation of the machine axis 144 occurs every 120milliseconds. Upon each revolution of the machine axis 144, a shiftregister in the controller is incremented by one virtual product. Forexample, FIGS. 3A and 3B show the base substrate advancing in themachine direction past a reference point 160 in the converting line 100.At the reference point 160, the first virtual product 150 a is presentat the reference point at a first time, t₁. At a second time, t₂, 120milliseconds after t₁, the second virtual product 150 b is present atthe same reference point 160, meanwhile the first virtual product 150 ahas progressed one pitch or 600 mm downstream in the machine direction.Continuing on, at a third time, t₃, 120 milliseconds after t₂, the thirdvirtual product 150 c is present at the same reference point 160,meanwhile the first and second virtual products 150 a, 150 b haveprogressed one pitch or 600 mm downstream in the machine direction. Theaforementioned increments continue as the base substrate 106 movesthrough the converting line 100. FIGS. 3A and 3B also show the additionof components in the form of front ears 158 to the first virtual product150 a.

FIGS. 4A and 4B show the advancement of the base substrate 106 in themachine direction past the inspection sensor 140. As discussed above,the inspection sensor 140 can be configured to detect the position ofthe components 158 on the base substrate 106. As such, the inspectionsensor 140 provides an inspection parameter 1000 to the communicationnetwork 154 via the remote I/O station 156, wherein the inspectionparameter 1000 corresponds with the sensed position of the component 158a. Because the position of the inspection sensor 140 along theconverting line 100 is known by the controller 142, the controller 142correlates the inspection parameters 1000 provided by the inspectionsensor 140 with the corresponding virtual products 150 based on thetimestamps of the inspection parameters. In the present example, theinspection sensor 140 detects the position 164 of the component 158 a onthe substrate 106, and the controller 142 determines the relativeposition of the component 158 a on the first virtual product 150 a. Therelative position in the present example is defined by the distancebetween a leading edge 162 a of the component 158 a and the virtualleading edge 168 a. If the relative position of the component on thevirtual product is not within desired limits, the controller cantemporarily adjust the speed at which the components are added to thebase substrate or provide a position move offset command to put thecomponents back with desired limits.

FIGS. 4A and 4B show the continued advancement from FIGS. 3A and 3B ofthe base substrate 106 in the machine direction, and in particular,advancement of the component 158 a on the first virtual product 150 apast the inspection sensor. FIG. 4A shows a first inspection parameter,RP1, having a corresponding timestamp, Ts1, being communicated to thecommunication network 154. RP1 is configured to provide an indication ofthe position of the component 158 a on the first virtual product 150 a.As discussed below, RP1 may not be immediately received by thecontroller 142. Simultaneously, the time reported by master controllerclock 1010 is Tc1. As discussed below, RP1 may not be immediatelyreceived by the controller 142.

Next, FIGS. 5A and 5B show the continued advancement from FIGS. 4A and4B of the base substrate 106 in the machine direction, and inparticular, advancement of the component 158 b of the second virtualproduct 150 b past the inspection sensor 140. FIG. 5A shows a secondinspection parameter, RP2, having a corresponding timestamp, Ts2, beingcommunicated to the communication network. RP2 provides an indication ofthe relative position of the component 158 b on the second virtualproduct 150 b. Again, RP2 may not be immediately received by thecontroller 142 from the communication network 154. Simultaneously, thetime reported by master controller clock 1010 is Tc2. Again, RP2 may notbe immediately received by the controller 142 from the communicationnetwork 154.

Next, FIGS. 6A and 6B show the continued advancement from FIGS. 5A and5B of the base substrate 106 in the machine direction, and inparticular, advancement of the component 158 c of the third virtualproduct 150 c past the inspection sensor 140. FIG. 6A shows a secondinspection parameter, RP3, having a corresponding timestamp, Ts3, beingcommunicated to the communication network 154. RP3 provides anindication of the relative position of the component 158 c on the thirdvirtual product 150 c have been detected. Again, RD3 may not beimmediately received by the controller 142 from the communicationnetwork 154. Simultaneously, the time reported by master controllerclock 1010 is Tc3. Again, RP3 may not be immediately received by thecontroller 142 from the communication network 154.

As previously mentioned, some amount of time may pass before thecontroller 142 receives the inspection parameters 1000 from thecommunication network 154. Such time delays may be the result of thenon-deterministic nature of the Ethernet IP network. There may also beadditional time before a controller analyzes the inspection parametersbased on the controller's program cycle or loop time. However,notwithstanding such time delays, once the controller 142 receives andanalyzes inspection parameters 1000, the controller can use thecorresponding timestamps of the inspection parameters 1000 to comparethe positions of components on the virtual products with setpoints. Forexample, the controller 142 may receive and analyze RP1 at some timeafter RP1 was provided to the communication network 154. However, alongwith RP1, the controller will receive Ts1, which is provided by thesensor clock 1008. Because the sensor clock 1008 is synchronized withthe master controller clock 1010, the controller 142 will be able tocorrelate RP1 with the virtual product 150 a. As discussed above, RP1provides an indication of the detection of the component 158 a on thefirst virtual product 150 a with a time stamp, Ts1. Thus, the controller142 can determine if the position of the component 158 a is withindesired limits.

In another example, the base substrate 106 is advancing in the machinedirection MD at a first speed, and the individual components 116 areadvancing from auxiliary substrate 108 to transfer mechanism at a secondspeed. The individual components 116 are combined with the substrate 106to form ears 158. And the controller 142 may receive and analyze RP2 atsome time after RP2 was provided to the communication network. However,along with RP2, the controller will receive Ts2, which is provided bythe sensor clock 1008. Because the sensor clock 1008 is synchronizedwith the master controller clock 1010, the controller 142 will be ableto correlate RP2 with the second virtual product 150 b. As discussedabove, RP2 provides an indication of the detection of the component 158b on the second virtual product 150 b with a time stamp, Ts2. Thus, ifthe controller 142 determines that the leading edge 162 b of component158 b is too close to the virtual leading edge 168 b of virtual product150 b, the controller can send a speed change command 1002 totemporarily reduce the speed of individual components 116 from thesecond speed to a third speed to adjust the placement of components 158onto the substrate. Once subsequently added components 158 aredetermined to in the correct position, the controller can increase thespeed of individual components 116 from the third speed to back to thesecond speed.

Building on the previous example, the controller 142 may receive andanalyze RP3 at some time after RP3 was provided to the communicationnetwork 154. However, along with RP3, the controller 142 will receiveTs3, which is provided by the sensor clock 1008. Because the sensorclock 1008 is synchronized with the master controller clock 1010, thecontroller will be able to correlate RP3 with the third virtual product150 c. As discussed above, RP3 provides an indication of the detectionof component 158 c on the third virtual product 150 c with a time stamp,Ts3. Thus, if the controller 142 determines that the leading edge 162 bof component 158 b is too far from the virtual leading edge 168 c ofthird virtual product 150 c, the controller can send a speed changecommand 1002 to temporarily increase the speed of individual components116 from the second speed to a third speed to adjust the placement ofcomponents 158 onto the substrate. Once subsequently added components158 are determined to in the correct position, the controller candecrease the speed of individual components 116 from the third speed toback to the second speed.

Because the inspection parameters 1000 have timestamps provided fromsensor clocks 1008 that are synchronized with the controller masterclock 1010, the controller 142 can correlate the inspection parameters1000 with the count data from the machine axis 144 without having toaccount for various system time delays, such as time delays in thecommunication network and controller loop times. In addition, thecontroller can be configured to account for time delays within theinspection sensor 140. As such when accounting for sensor time delays,the correlated location of the components 158 on the substrates and/orcomponents may be accurate to within the accuracy of the sensor clock1008 with respect to the controller master clock 1010. For example, thehardware and/or software configurations of an inspection sensor maycreate a time delay between the actual detection of a component and thereporting of the inspection parameter onto the communication network.Such a sensor time delay can be accounted for in the controller bymerely including an offset equal to the time delay when comparing thetimestamps.

Expanding on the above discussion of the example provided in FIGS.3A-6B, the estimated accuracies of the clocks 1008, 1010 and the speedof the substrate 106 in the machine direction can be used to determine aminimum length accuracy where components 158 are located on the virtualproducts 150. More particularly, the minimum length can be calculated bymultiplying the estimated clock accuracy by the speed of the substrate.For example, where the clock accuracy meets the software implementationof IEE1588, the clocks may be assured to be accurate within 0.1millisecond. Using the example speed above of 300 meters per minute, thevirtual segment length in the machine direction is calculated to be 0.5mm. In such a case, the position of a component 150 b, such ascorresponding with RP2 in the example above, may be known to within 0.5mm in the machine direction MD on the base substrate.

As previously mentioned, the systems and methods herein may be used tomonitor various types of substrates and components during themanufacture of various different products. For the purposes of aspecific illustration, FIG. 7 shows one example of a disposableabsorbent article 750, such as described in U.S. Patent Publication No.US2008/0132865 A1, in the form of a diaper 752 that may be constructedfrom substrates and components monitored according to the systems andmethods disclosed herein. In particular, FIG. 7 is a plan view of oneembodiment of a diaper 752 including a chassis 754 shown in a flat,unfolded condition, with the portion of the diaper 752 that faces awearer oriented towards the viewer. A portion of the chassis structureis cut-away in FIG. 7 to more clearly show the construction of andvarious features that may be included in embodiments of the diaper.

As shown in FIG. 7, the diaper 752 includes a chassis 754 having a firstear 756, a second ear 758, a third ear 760, and a fourth ear 762. Toprovide a frame of reference for the present discussion, the chassis isshown with a longitudinal axis 764 and a lateral axis 766. The chassis754 is shown as having a first waist region 768, a second waist region770, and a crotch region 772 disposed intermediate the first and secondwaist regions. The periphery of the diaper is defined by a pair oflongitudinally extending side edges 774, 776; a first outer edge 778extending laterally adjacent the first waist region 768; and a secondouter edge 780 extending laterally adjacent the second waist region 770.As discussed above, the pitch length, PL, of the absorbent article 750may be defined by the distance between the first outer edge 778 and thesecond outer edge 780. As shown in FIG. 7, the chassis 754 includes aninner, body-facing surface 782, and an outer, garment-facing surface784. A portion of the chassis structure is cut-away in FIG. 7 to moreclearly show the construction of and various features that may beincluded in the diaper. As shown in FIG. 7, the chassis 754 of thediaper 752 may include an outer covering layer 786 including a topsheet788 and a backsheet 790. An absorbent core 792 may be disposed between aportion of the topsheet 788 and the backsheet 790. As discussed in moredetail below, any one or more of the regions may be stretchable and mayinclude an elastomeric material or laminate as described herein. Assuch, the diaper 752 may be configured to adapt to a specific wearer'sanatomy upon application and to maintain coordination with the wearer'sanatomy during wear.

As previously mentioned, the chassis 754 of the diaper 752 may includethe backsheet 790, shown for example, in FIG. 7. In some embodiments,the backsheet is configured to prevent exudates absorbed and containedwithin the chassis from soiling articles that may contact the diaper,such as bedsheets and undergarments. Some embodiments of the backsheetmay be fluid permeable, while other embodiments may be impervious toliquids (e.g., urine) and comprises a thin plastic film. Some backsheetfilms may include those manufactured by Tredegar Industries Inc. ofTerre Haute, Ind. and sold under the trade names X15306, X10962, andX10964. Other backsheet materials may include breathable materials thatpermit vapors to escape from the diaper while still preventing exudatesfrom passing through the backsheet. Exemplary breathable materials mayinclude materials such as woven webs, nonwoven webs, composite materialssuch as film-coated nonwoven webs, and microporous films. Suitablebreathable composite materials are described in greater detail in PCTApplication No. WO 95/16746, published on Jun. 22, 1995 in the name ofE. I. DuPont and U.S. Pat. No. 5,865,823, both of which are herebyincorporated by reference herein. Other breathable backsheets includingnonwoven webs and apertured formed films are described in U.S. Pat. Nos.5,571,096 and 6,573,423, which are all hereby incorporated by referenceherein.

The backsheet 790, or any portion thereof, may be stretchable in one ormore directions. In one embodiment, the backsheet may comprise astructural elastic-like film (“SELF”) web. Embodiments of SELF webs aremore completely described in U.S. Pat. Nos. 5,518,801; 5,723,087;5,691,035; 5,916,663; and 6,027,483, which are all hereby incorporatedby reference herein. In some embodiments, the backsheet may compriseelastomeric films, foams, strands, nonwovens, or combinations of theseor other suitable materials with nonwovens or synthetic films.Additional embodiments include backsheets that comprise a stretchnonwoven material; an elastomeric film in combination with an extensiblenonwoven; an elastomeric nonwoven in combination with an extensiblefilm; and/or combinations thereof. Details on such backsheet embodimentsare more completely described in U.S. Publication Nos. US2007/0287348A1;US2007/0287982A1; and US2007/0287983A1, which are all herebyincorporated by reference herein. The backsheet 790 may be joined withthe topsheet 788, the absorbent core 792, and/or other elements of thediaper 752 in various ways. For example, the backsheet may be connectedwith a uniform continuous layer of adhesive, a patterned layer ofadhesive, or an array of separate lines, spirals, or spots of adhesive.One embodiment utilizes an open pattern network of filaments of adhesiveas disclosed in U.S. Pat. No. 4,573,986, which is hereby incorporated byreference herein. Other embodiments utilize several lines of adhesivefilaments which are swirled into a spiral pattern, as is illustrated bythe apparatus and methods shown in U.S. Pat. Nos. 3,911,173; 4,785,996;and 4,842,666, which are all hereby incorporated by reference herein. Insome embodiments, the backsheet is connected with heat bonds, pressurebonds, ultrasonic bonds, dynamic mechanical bonds, or any other suitableattachment means or a combination thereof.

The topsheet 788 may be constructed to be compliant, soft feeling, andnon-irritating to the wearer's skin. Further, all or at least a portionof the topsheet 788 may be liquid pervious, permitting liquid to readilypenetrate therethrough. As such, the topsheet may be manufactured from awide range of materials, such as porous foams; reticulated foams;apertured nonwovens or plastic films; or woven or nonwoven webs ofnatural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g.,polyester or polypropylene fibers), or a combination of natural andsynthetic fibers. One example of a topsheet including a web of staplelength polypropylene fibers is manufactured by Veratec, Inc., a Divisionof International Paper Company, of Walpole, Mass. under the designationP-8. Examples of formed film topsheets are described in U.S. Pat. Nos.3,929,135; 4,324,246; 4,342,314; 4,463,045; and 5,006,394, all of whichare hereby incorporated by reference herein. Other topsheets may be madein accordance with U.S. Pat. Nos. 4,609,518 and 4,629,643, both of whichare hereby incorporated by reference herein.

In some embodiments, the topsheet 788 is made of a hydrophobic materialor is treated to be hydrophobic in order to isolate the wearer's skinfrom liquids contained in the absorbent core. If the topsheet is made ofa hydrophobic material, at least the upper surface of the topsheet maybe treated to be hydrophilic so that liquids will transfer through thetopsheet more rapidly. The topsheet can be rendered hydrophilic bytreating it with a surfactant or by incorporating a surfactant into thetopsheet. A more detailed discussion of such a treatment andhydrophilicity is contained in U.S. Pat. Nos. 4,988,344 and 4,988,345,all of which are hereby incorporated by reference herein. A moredetailed discussion of some methods for incorporating surfactant in thetopsheet can be found in U.S. Statutory Invention Registration No.H1670, which was published on Jul. 1, 1997, in the names of Aziz et al.,all of which are hereby incorporated by reference herein. In someembodiments, the topsheet 788 may include an apertured web or film thatis hydrophobic. This may be accomplished eliminating the hydrophilizingtreatment step from the production process and/or applying a hydrophobictreatment to the topsheet, such as a polytetrafluoroethylene compoundlike SCOTCHGUARD or a hydrophobic lotion composition, as describedbelow. A more detailed discussion of various apertured topsheets can befound in U.S. Pat. Nos. 5,342,338; 5,941,864; 6,010,491; and 6,414,215,all of which are hereby incorporated by referenced herein.

The absorbent core 792 may include absorbent material that is generallycompressible, conformable, non-irritating to the wearer's skin, andcapable of absorbing and retaining liquids such as urine and other bodyexudates. The absorbent core 792 can also be manufactured in a widevariety of sizes and shapes (e.g., rectangular, hourglass, T-shaped,asymmetric, etc.). The absorbent core may also include a wide variety ofliquid-absorbent materials commonly used in disposable diapers and otherabsorbent articles. In one example, the absorbent core includescomminuted wood pulp, which is generally referred to as airfelt.Examples of other absorbent materials include creped cellulose wadding;meltblown polymers, including coform; chemically stiffened, modified orcross-linked cellulosic fibers; tissue, including tissue wraps andtissue laminates; absorbent foams; absorbent sponges; superabsorbentpolymers; absorbent gelling materials; or any other known absorbentmaterial or combinations of materials. Exemplary absorbent structuresare described in U.S. Pat. Nos. 4,610,678; 4,673,402; 4,834,735;4,888,231; 5,137,537; 5,147,345; 5,342,338; 5,260,345; 5,387,207; and5,650,222, all of which are hereby incorporated by reference herein.

The absorbent core 792 may also have a multiple layered construction. Amore detailed discussion of various types of multi-layered absorbentcores can be found in U.S. Pat. Nos. 5,669,894; 6,441,266; and5,562,646; European Patent No. EP0565606B1; U.S. Patent Publication No.2004/0162536A1; 2004/0167486A1; and PCT Publication No. WO 2006/015141,which are all hereby incorporated by reference herein. In someembodiments, the absorbent article includes an absorbent core that isstretchable. In such a configuration, the absorbent core may be adaptedto extend along with other materials of the chassis in longitudinaland/or lateral directions. The absorbent core can also be connected withthe other components of the chassis various ways. For example, thediaper may include a “floating core” configuration or a “bucket”configuration wherein the diaper includes an anchoring system that canbe configured to collect forces tending to move the article on thewearer. The absorbent article may also include an elastic waist feature702 shown in FIG. 7 in the form of a waist band 794 and may provideimproved fit and waste containment. The elastic waist feature 702 may beconfigured to elastically expand and contract to dynamically fit thewearer's waist. The elastic waist feature 702 can be incorporated intothe diaper in accordance with the methods discussed herein and mayextend at least longitudinally outwardly from the absorbent core 792 andgenerally form at least a portion of the first and/or second outer edges778, 780 of the diaper 752. In addition, the elastic waist feature mayextend laterally to include the ears. While the elastic waist feature702 or any constituent elements thereof may comprise one or moreseparate elements affixed to the diaper, the elastic waist feature maybe constructed as an extension of other elements of the diaper, such asthe backsheet 790, the topsheet 788, or both the backsheet and thetopsheet. In addition, the elastic waist feature 702 may be disposed onthe outer, garment-facing surface 784 of the chassis 754; the inner,body-facing surface 782; or between the inner and outer facing surfaces.The elastic waist feature 702 may be constructed in a number ofdifferent configurations including those described in U.S. PatentPublication Nos. 2007/0142806; 2007/0142798; and 2007/0287983, all ofwhich are hereby incorporated by reference herein.

Although the first and second ears 756, 158 as well as the third andfourth ears 760, 762 shown in FIG. 7 are illustrated as being integrallyformed with the chassis 754, it is to be appreciated that otherembodiments may include ears that are discrete elements connected withthe chassis. In some embodiments, the ears are configured to bestretchable. The ears may also include one or more fastener elementsadapted to releasably connect with each other and/or other fastenerelements on the chassis. A more detailed discussion of stretchable earscan be found in U.S. Pat. Nos. 4,857,067; 5,151,092; 5,674,216;6,677,258; 4,381,781; 5,580,411; and 6,004,306, which are all herebyincorporated by reference herein. The ears may also include variousgeometries and arrangements of stretch zones or elements, such asdiscussed in U.S. Pat. Publication Nos. US2005/0215972A1 andUS2005/0215973A1, which are all hereby incorporated by reference herein.

As shown in FIG. 7, the diaper 752 may include leg cuffs 796 that mayprovide improved containment of liquids and other body exudates. The legcuffs 796 may be disposed in various ways on the diaper 752. Forexample, the leg cuffs 796 may be disposed on the outer, garment-facingsurface 784 of the chassis 754; the inner, body-facing surface 782; orbetween the inner and outer facing surfaces. Leg cuffs 796 may also bereferred to as leg bands, side flaps, barrier cuffs, or elastic cuffs.U.S. Pat. No. 3,860,003, which is hereby incorporated by referenceherein, describes a disposable diaper that provides a contractible legopening having a side flap and one or more elastic members to provide anelasticized leg cuff (a gasketing cuff). U.S. Pat. Nos. 4,808,178 and4,909,803, which are both hereby incorporated by reference herein,describe disposable diapers having “stand-up” elasticized flaps (barriercuffs). U.S. Pat. Nos. 4,695,278 and 4,795,454, which are both herebyincorporated by reference herein, describe disposable diapers havingdual cuffs, including gasketing cuffs and barrier cuffs. In someembodiments, it may be desirable to treat all or a portion of the legcuffs with a lotion, as described above. In addition to leg cuffs,diaper can also include an elastic gasketing cuff with one or moreelastic strands positioned outboard of the barrier cuff. The leg cuffsmay be treated with a hydrophobic surface coating, such as described inU.S. Pat. Publication No. 20060189956A1, which is hereby incorporated byreference herein.

The diaper 752 may be provided in the form of a pant-type diaper or mayalternatively be provided with a re-closable fastening system, which mayinclude fastener elements in various locations to help secure the diaperin position on the wearer. For example, fastener elements may be locatedon the first and second ears and may be adapted to releasably connectwith one or more corresponding fastening elements located in the secondwaist region. It is to be appreciated that various types of fasteningelements may be used with the diaper. In one example, the fasteningelements include hook & loop fasteners, such as those available from 3Mor Velcro Industries. In other examples, the fastening elements includeadhesives and/or tap tabs, while others are configured as amacrofastener or hook (e.g., a MACRO or “button-like” fastener). Someexemplary fastening elements and systems are disclosed in U.S. Pat. Nos.3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527; 5,151,092; and5,221,274, which are all hereby incorporated by reference herein.Additional examples of fasteners and/or fastening elements are discussedin U.S. Pat. Nos. 6,251,097 and 6,432,098; and U.S. Patent PublicationNos. 2007/0078427 and 2007/0093769, which are all hereby incorporated byreference herein. Other fastening systems are described in more detailin U.S. Pat. Nos. 5,595,567; 5,624,427; 5,735,840; and 5,928,212, whichare all hereby incorporated by reference herein. The fastening systemmay also provide a means for holding the article in a disposalconfiguration as disclosed in U.S. Pat. No. 4,963,140, which is herebyincorporated by reference herein.

It is to be appreciated that the methods and systems disclosed hereinmay be utilized to monitor the quality of substrates and components aswell as respective placements of substrates and/or components during themanufacture of absorbent articles, such as for example, topsheets,backsheets, absorbent cores, ears, waist features, and graphics printedthereon. It is also to be appreciated that the phasing systems andmethods described herein may also be utilized in combination with othertypes of control systems and methods, such as described in U.S. patentapplication identified by Attorney Docket No. 11348, entitled “SYSTEMSAND METHODS FOR CONTROLLING REGISTRATION OF ADVANCING SUBSTRATES INABSORBENT ARTICLE CONVERTING LINES,” filed on Jun. 2, 2009, and U.S.patent application identified by Attorney Docket No. 11340, entitled“SYSTEMS AND METHODS FOR DETECTING AND REJECTING DEFECTIVE ABSORBENTARTICLES FROM A CONVERTING LINE,” filed on Jun. 2, 2009. Further, thetime synchronization features of the methods and systems describedherein may be utilized in other types of control systems and methodssuch as for example: data storage and correlation methods with repeatapplication devices and multiple application stations such as describedin U.S. Pat. No. 6,829,516; raw material database integration such asdescribed in U.S. Pat. No. 7,162,319; web guide control methods andsystems such as described in U.S. Pat. No. 6,801,828; and data miningand trending methods and systems such as described in U.S. Pat. No.6,845,278.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A method for phasing absorbent products from a web convertingmanufacturing process, the method comprising the steps of: providing acommunication network; connecting a sensor with the communicationnetwork, the sensor including a sensor clock; connecting a controllerwith the communication network, the controller including a controllerclock; synchronizing the sensor clock with the controller clock suchthat the reported time of the controller clock and the sensor clock arecorrelated; advancing a substrate in a machine direction through aconverting process at a first speed; virtually segmenting the substrateinto a plurality of virtual products along the machine direction;virtually dividing the virtual products into a plurality of virtualsegments along the machine direction; advancing a series of componentparts in the machine direction at a second speed, the component partsspaced from each other at a relatively constant distance; sequentiallyadding component parts to the substrate; inspecting the substrate andcomponent parts with the sensor; communicating inspection parametersfrom the sensor to the communication network; assigning a timestamp toeach inspection parameter, each timestamp based on the sensor clock;receiving the inspection parameters and corresponding timestamps fromthe communication network into the controller; correlating eachinspection parameter with one virtual segment based on the timestamp ofthe inspection parameter; identifying component positions in virtualsegments based on the inspection parameters; adjusting the placement ofthe component parts on the virtual products; cutting the substrate withcomponent parts added thereto into discrete absorbent articles; andpackaging the discrete absorbent articles.
 2. The method of claim 1,wherein the step of adjusting the placement further comprises changingthe second speed of the component parts to a third speed and changingfrom the third speed back to the second speed.
 3. The method of claim 1,wherein the third speed is greater than the second speed.
 4. The methodof claim 1, wherein the third speed is less than the second speed. 5.The method of claim 1, further comprising the step of adjusting thetimestamps associated with the inspection parameters based on a sensortime delay.
 6. The method of claim 1, wherein the component partsinclude parts added as a continuous web of material and parts added as adiscontinuous web of material.
 7. The method of claim 1, wherein thecommunication network is non-deterministic.
 8. The method of claim 1,wherein the absorbent articles are diapers.
 9. The method of claim 8,wherein the first substrate forms backsheets of the diapers.
 10. Themethod of claim 8, wherein the components are ears.